Power cord having thermochromatic material

ABSTRACT

A temperature sensing extension cord comprising of an extension cord having an electrical conductor, a male electrical plug in electrical communication with the electrical conductor, and a female socket in electrical communication with the electrical conductor; and a thermochromatic material in contact with the extension cord, the thermochromatic material configured to change from a first color to a second color upon detecting a temperature at or above a threshold temperature.

REFERENCE TO CO-PENDING PATENT APPLICATIONS

The patent application claims the benefit of U.S. Provisional Patentapplication Ser. No. 60/836,801, filed on Aug. 10, 2006 and entitled“Electrical Cord,” the entire disclosure of which is incorporated hereinby reference. The patent application is being filed concurrently filedwith U.S. patent application Ser. No. 11/891,676 entitled “AdjustableAnchor for Extension Cord,” and is being filed concurrently filed withU.S. patent application Ser. No. 11/891,675 entitled “Temporary LightingFixture,” and is being filed concurrently filed with U.S. patentapplication Ser. No. 11/891,681 entitled “Electrical Adaptor Having anAnchor,” and is being filed concurrently filed with U.S. patentapplication Ser. No. 11/891,625 entitled “Extension Cord Having aTemperature Indicator,” and is being filed concurrently filed with U.S.patent application Ser. No. 11/891,623 entitled “Out-of-Round ElectricalTwist-Lock Adaptor,” and is being filed concurrently filed with U.S.patent application Ser. No. 11/891,667 entitled “Ground FaultInterrupter for Extension Cords.”

BACKGROUND

Electrical cords, and in particular extension cords, are usedextensively in many applications, in both residential and commercialapplications, because they provide a way to deliver electrical powerfrom an electrical outlet to equipment that is far away from the outlet.However, there are significant issues surrounding safety and conveniencethat are associated with the use of extension cords.

One safety issue often associated with construction sites is the use ofmany extension cords because of the large number of tools that needelectricity to operate. Typically these devices may not be plugged intothe same cord because they would, in combination, require too muchcurrent to be safely provided through a single cord. This safety concernis especially true at construction sites where at least some of theequipment draws a large amount of power.

Furthermore, additional extension cords may be necessary becausedifferent pieces of equipment require different amounts of voltage tooperate. For example, most electrically operated devices require a 120Vsource. However, some devices use a large amount of power and thusrequire 208V or 240V supplies.

Extensive usage of extension cords increases the probability of anelectrical fault, cord degradation, or cord overloading. Corddegradation and failure when using a high-amperage power source and cordcan cause fires, electrical shocks, and other hazards. Existing safetyfuses and ground fault interrupter (GFI) circuits within electricalcords can sense sudden catastrophic electrical events, such as powerfailures, power surges, or other electrical or physical events caused onthe source side of the electrical cord. These safety devices areintegrated into the electrical cord and allow an electrical cord todisconnect upon occurrence of an electrical event.

Fuses and GFI circuits may not protect against various types of gradualfailures, such as due to physical wear or thermal degradation. Suddenshort circuits at the load end of the cord remain unprotected by thesedevices as well. Additionally, fuses and GFI circuits are typicallyconnected in series with the cord so that if the fuse or GFI circuit istripped, the entire cord is disabled. When a cord has multiplereceptacles providing power to different tools and devices, a failure inone of the devices would trip the fuse or GFI and disconnect power toall of the receptacles and all of the devices that are plugged into thecord. Such an event can be startling and potentially hazardous to otherusers.

Heating is another safety problem for both commercial and residentialextension cords even when the cord is overloaded. Extension cords thathave a flaw such as a loose connector, partially broken wire, or kinkhave a point of increased resistance that causes resistive heating evenwhen the current drawn through the cord is within its rated capacity.Such conditions can cause the extension cord to overheat and potentiallyignite starting a fire, especially if the extension cord is adjacent aflammable material such as wood, clothing, or chemicals.

Yet another problem relates to extension cords that include lockingmechanisms holding the male electrical plug portion in a female socket.These extension cords, called “twist lock” cords, prevent disconnectionof the cord in case someone trips on the cord or the cord is otherwiseunintentionally pulled from its socket connection to a power source,such as an electrical generator or a wall socket. When connecting atwist lock plug, the user inserts the plug into the receptacle andtwists it to lock it in place to prevent it from being accidentallypulled from the receptacle. The difficulty is that the cross-section ofthe housing for a male twist lock plug is typically circular. Suchconfigurations make it difficult to make a visual determination ofwhether the plug was properly twisted to lock it into the receptacle.

Additionally, construction workers and even casual residential usersoccasionally need to set up temporary power distribution for tools anduse temporary lights to illuminate a room, work area, or work product.In some applications, the workers simply lay out a bunch of extensioncords on the ground, which is dangerous because they are trippinghazards that the workers can fall over. The cords are also easilydisconnected from one another and from their tools causing an unexpectedloss of power. For lighting, the workers either plug in temporary lampsthat rest on the floor, a table top, or create a temporary string oflights by hard wiring sockets to a pair of wires and hanging them from aceiling or other structure. However, having to build a dedicated, hardwired light string is expensive and cumbersome.

SUMMARY

One aspect of the claimed invention is a temperature sensing extensioncord comprising an extension cord having an electrical conductor, a maleelectrical plug in electrical communication with the electricalconductor, and a female socket in electrical communication with theelectrical conductor. A thermochromatic material is in contact with theextension cord. The thermochromatic material is configured to changefrom a first color to a second color upon detecting a temperature at orabove a threshold temperature.

Another aspect of the invention is a method of monitoring thetemperature of an extension cord. The method comprises applying athermochromatic material to an extension cord; sensing a temperature ofat least a portion of the extension cord with the thermochromaticmaterial; and changing a color of the thermochromatic material upondetecting a temperature at or above a threshold temperature.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of an extension cord showing a male plug, femalesockets, and socket blocks of the cord, in which various aspects of thepresent disclosure can be implemented;

FIGS. 2A-2F are schematic views of various extension cords havingintegrated ground fault circuit protection;

FIGS. 3A-3B are schematic views of circuit sections shown in FIG. 2A;

FIG. 4 is a perspective view of an alternative embodiment of theextension cord shown in FIG. 1 having an optional adapter for the maleplug of the extension cord;

FIGS. 5A and 5B are front views of alternative socket blockconfigurations having circuit identifying marks for use with theextension cord shown in FIG. 1;

FIG. 6 is a perspective view of a female socket and socket block with anoptional cap and an optional mooring member;

FIG. 7 is a front view of the extension cord shown in FIG. 5 being heldoff the ground by use of mooring members attached to the socket blocksof the cord;

FIG. 8A is a perspective view of a prior art twist lock cord;

FIG. 8B is a perspective side view of a male connector for a twist lockcord;

FIG. 8C is a functional schematic view of showing locked and unlockedpositions of the male twist lock connector shown in FIG. 8B;

FIG. 9A-9B are schematic views of electricity distribution from anelectrical generator;

FIGS. 10A-10D are schematic views of various extension cords havingintegrated thermal failure detection;

FIGS. 11A-11C are schematic views of various electrical cords havingintegrated thermal failure detection;

FIG. 12 is a front view of an extension cord having a thermochromaticmaterial to indicate temperature of the cord;

FIG. 13A is a side view of a female socket having an adjustable anchorin a closed position;

FIG. 13B is a front view of the female socket shown in FIG. 13A with theadjustable anchor in the closed position;

FIG. 14A is a side view of the female socket shown in FIG. 13A when theadjustable anchor is in an open position;

FIG. 14B is a front view of the female socket shown in FIG. 13A when theadjustable anchor is in an open position;

FIG. 15 is a side view of an extension cord having intermittently spacedsockets and adjustable anchors in an open position and mounted on avertical surface;

FIG. 16 is a side view of an extension cord having intermittently spacedsockets and adjustable anchors in a closed position suspended;

FIG. 17 is a side view of an electrical adaptor having an anchor and afastener;

FIGS. 18A and 18B are perspective and side views, respectively, of thefastener shown in FIG. 17;

FIG. 19 is a side view of the electrical adaptor shown in FIG. 17connecting two extension cords;

FIG. 20 is a side view of an alternative embodiment of the adaptor ofshown in FIG. 17;

FIG. 21 is a side view of another alternative embodiment of the adaptorshown in FIG. 17; and

FIG. 22 is a view of a temporary lighting fixture having a fastener tosecure the fixture to a female socket

DETAILED DESCRIPTION

Various embodiments will be described in detail with reference to thedrawings, wherein like reference numerals represent like parts andassemblies throughout the several views. Reference to variousembodiments does not limit the scope of the claims attached hereto.Additionally, any examples set forth in this specification are notintended to be limiting and merely set forth some of the many possibleembodiments for the appended claims.

Referring to the drawings, FIG. 1 shows an exemplary extension cord 10in which aspects of the present disclosure can be implemented. Theexemplary cord 10 provides electrical connections at a plurality oflocations along its length. The extension cord 10 includes a male plug12 attached to one end within a housing 13, with socket blocks 22housing female sockets 20 disposed along the cord.

The male plug 12 electrically connects to two or more conducting wiresand an optional ground wire, as discussed herein. The conducting wiresand optional ground wire are typically bound together into a single cord16 that is covered by an insulated sheathing 18. The gauge of theconducting wires is chosen based on the length and expected use of theextension cord. Thicker wires are appropriate for longer cords and forcords used in heavy-duty applications that have large powerrequirements. Finer gauged wires are used for household extension cords.

Typically, the socket blocks 22, insulated sheathing 18, and the housing13 of the male plug 12 are constructed from plastics or polymers. In onepossible embodiment, the male plug 12, socket blocks 22, and insulatedsheathing 18 are molded together to form one continuous piece. Thiscontinuously molded embodiment of the extension cord is desirablebecause of the elimination of joints between the sheathing and the plugor socket blocks. Such joints often weaken the cord integrity and mayprovide an avenue for the entry of moisture into the interior of thecord which may short or damage the conducting wires.

The socket blocks 22 reside at intervals along the length of theextension cord 10. These intervals are typically regular, but may alsobe irregular. Each socket block 22 houses two female sockets 20. Inother possible embodiments, however, the socket blocks 22 house onefemale socket 20 or three or more female sockets 20. Yet other possibleembodiments of the extension cord 10 include a mixture of sockets blockscontaining different numbers of female sockets, such as one femalesocket in some of the socket blocks and two female sockets in othersocket blocks.

Each of the female sockets 20 is an electrical socket that electricallyconnects to at least two wires in the cord 10. In a possible embodiment,one or more of the female sockets 20 is a twist lock socket, asdescribed herein. In another possible embodiment, one or more of thefemale sockets 20 is a three prong socket and includes the optionalground wire. Additional embodiments of the extension cord describedherein are discussed in U.S. Pat. No. 5,902,148, the entire disclosureof which is hereby incorporated by reference.

Safety devices reside at various locations along the extension cord 10,which is configurable for use with such devices. The safety devicesreside at any of a variety of locations along the extension cord,although in some embodiments the devices reside near the male plug 12 orfemale socket 20 due to the propensity for electrical fault or failureoccurrences in those locations. In a possible embodiment, the housing 13for the male plug 12 encloses a safety device integrated with theextension cord 10. In another possible embodiment, the socket block 22or other female connector housing encloses a safety device as well. Invarious embodiments, the housings 13 and socket block 22 enclose groundfault circuit interrupters. In other embodiments, the housings 13 andsocket block 22 include a thermal or temperature indicator circuitformed by the combination of a thermal switch and an indicator, or someother heat sensing configuration. Additionally, the male plug 12 caninclude a male twist lock configuration, whether that configuration is astandard configuration or a non-round configuration as described in moredetail herein. The female sockets 20 can include a female twist lockconfiguration, whether that configuration is a standard configuration ora configuration adapted to mate with a non-round male configuration asdescribed in more detail herein.

In an application of the cord 10, light sockets can be plugged into oneor more of the female sockets 20. The light sockets can include a clampor other retaining member to secure the light socket to the femalesocket blocks 22. In one possible embodiment, the female socket 20 caninclude a detent that the clamp mates with and snaps into.Alternatively, the clamp or retaining member can be connected to thefemale socket 20 and receive the light socket. The light socket caninclude a basket or similar structure to protect a light bulb insertedin the light socket. One or more light sockets can also be packaged withthe electrical cord 10 in a kit.

Examples of electrical connection configurations between the femalesockets 20 and the conducting wires 14 a-14 g that include ground faultcircuit interrupters 30 are provided in FIGS. 2A-2F.

One embodiment of the extension cord 10 of the present disclosure hasthree conducting wires and is illustrated in FIG. 2A. This extensioncord 10 can be used, for example, with a single phase, three wire120/240V service. Various embodiments of the extension cord 10 can beused with other service ratings as well, whether the service ratingdefines a voltage different than 120/240V, current capacity, phase, orany other operating characteristic. This type of service is oftenavailable in the United States as the primary connection from electricaltransmission lines to residential and commercial properties. Theextension cord includes three conducting wires 14 a-c connecting themale plug 12 to the female sockets 20 a-c. The female sockets 20 a-creside within socket blocks 22, which also include ground fault circuitinterrupters 30 a-d.

In this configuration, one of the conducting wires 14 a is a neutralwire that is typically held at or near ground. The other two conductingor circuit wires 14 b, 14 c are held at about 120V above ground. Theselatter two wires are typically called “hot” or active wires because theyprovide a non-zero voltage drop across any grounded object. Each circuitwire is used to establish a separate circuit to which female sockets areattached.

Female sockets 20 a and 20 b are electrically connected to differentactive wires to create a cord 10 with two electrically isolatedcircuits. One or more female sockets 20 a of extension cord 10electrically connect in parallel to the neutral wire 14 a and one of the120V active wires 14 b. One or more female sockets 20 b electricallyconnect in parallel to the neutral wire 14 a and the other 120V activewire 14 c. Each of the female sockets 20 a, 20 b is capable of providing120 volts to electrically operated devices plugged into that socket. Inthe embodiment shown, one female socket 20 a or 20 b is included in eachsocket block 22.

One or more female sockets 20 c are capable of providing 240 volts, inaddition to the female sockets 20 a and 20 b which provide 120 volts.The 240 volt female socket 20 c electrically connects in parallel toboth of the 120V active wires 14 b and 14 c (and not to the neutral wire14 a) and provides 240 volts because the 120V circuit wires are 180° outof phase. Many heavy-duty tools and appliances, such as clothes dryers,require 240 volts, while the majority of electrically operated devicesin the United States operate with 120 volts. Only one cord 10 is neededto operate pieces of equipment that have different voltage ratings.

Each female socket 20 a-c of FIG. 2A includes ground fault circuitinterrupters 30 a-d incorporated within each socket block 22. The groundfault circuit interrupters 30 a-d detect sudden imbalances in currentflow such as can be caused by grounding of the load. This happens, forexample, by a user accidentally stepping in water or otherwise causing agrounding path. The ground fault circuit interrupters 30 a-d coupleacross the parallel electrical leads branching from the neutral wire 14a and conducting wire 14 b. Each ground fault circuit interrupter 30 a-dincludes a transformer 32, sense circuitry 34, one or more switches 36,and one or more solenoids 38. Operation of the components of the groundfault circuit interrupters 30 a-d is discussed in greater detail belowin FIGS. 3A-3B.

The ground fault circuit interrupters 30 a-d electrically isolate thefemale sockets 20 a and 20 b. If ground fault circuit interrupter 30 asenses a current imbalance to socket 20 a within the same socket block22, it interrupts current flow to that socket. Electrical connection tosocket 20 a associated with ground fault circuit interrupter 30 d is notinterrupted because it is formed from an electrical circuit parallel tothe circuit disconnected by ground fault circuit interrupter 30 a. Anelectrical tool is capable of being used if connected to any femalesocket 20 a-b associated with the non-interrupting ground fault circuitinterrupters 30 b-d. Various embodiments also could include an arc faultinterrupter in place of the ground fault circuit interrupter 30.

Extension cords 10 can also be made for use with voltage services otherthan the typical 120/240 volt service, and can include ground faultcircuit interrupters in various locations along the extension cord. Oneexample is a 120/208 volt service which is often configured as athree-phase, four-wire system. FIGS. 2B-2D illustrate alternativeembodiments of cords for use with this type of service.

FIG. 2B shows an exemplary embodiment of a cord 10 for use with afour-wire service. The cord is substantially similar to the onedescribed in conjunction with FIG. 2A, except that has a neutral wire 14d and three 120V conducting wires 14 e, 14 f and 14 g. Three different120V circuits can be made. One or more female sockets 20 f electricallyconnect in parallel to neutral wire 14 d and active wire 14 e, one ormore female sockets 20 g electrically connect in parallel to neutralwire 14 d and active wire 14 f, and one or more female sockets 20 helectrically connect in parallel to neutral wire 14 d and active wire 14g. The four circuits corresponding to sockets 20 f, 20 g, and 20 h,respectively, are electrically isolated due to these parallelconnections. In one possible embodiment, an additional female socket 20i electrically connects in parallel between any two of the active wires14 e-14 g, such as wires 14 e and 14 f shown. The socket 20 i provides208 volts to any electrically operated devices plugged into the socket.Ground fault circuit interrupters 30 e-h are coupled across each socket20 f-i, and operate as described in conjunction with FIGS. 2A and 3A-B.As described above, each of the ground fault circuit interrupters 30 e-honly disconnects electricity to the associated socket 20 f and 20 g dueto the parallel connection to the conducting wires 14 d-g.

In an alternative embodiment, the cord 10 has a separate neutral wireassociated with each conducting wire 14 e-14 g. For example, a cord 10having three conductors 14 d-14 g would also include three neutralwires. Each female socket 20 would have a contact connected between theconducting wire and the neural associated with that conducting wire.

FIG. 2C shows another possible embodiment of a cord 10 for use with afour wire service as described in conjunction with FIG. 2B. In thisembodiment, each socket block 22 incorporates multiple female sockets 20j-m, which connect in parallel within each socket block 22 and to theconducting wires 14 d-g. Separate ground fault circuit interrupters 30i-l are associated with each female socket 20 j-m, respectively. In thisconfiguration, one female socket 20 can be disabled within a socketblock 22 by a ground fault circuit interrupter 30 while the other femalesocket within the same socket block 22 remains active. All femalesockets 20 in the other socket blocks 22 also remain active.

In an alternate embodiment (not shown), one ground fault circuitinterrupter can be included in each socket block, and is associated withtwo or more female sockets. In such a configuration, both sockets withinthe socket block disable upon detection of a fault by a ground faultcircuit interrupter.

FIG. 2D shows a further possible embodiment of a cord 10 for use with afour wire service as described in conjunction with FIG. 3B. In thisembodiment, female sockets 20 n-p are distributed along the cord 10, andelectrically connected to two of the wires 14 d-g. A ground faultcircuit interrupter 30 m couples across the wires 14 d-g, and resideswithin the housing 13 of the male plug 12. In this configuration, theground fault circuit interrupter 30 m detects a zero sum current acrossall of the conducting wires 14 e-g and the neutral wire 14 d. Upondetection of a current change, the ground fault circuit interrupter 30 mdisconnects the conducting wires 14 e-g, deactivating all of the sockets20 n-p along the cord 10.

Two further embodiments are depicted in FIGS. 2E and 2F which include agrounding wire 24 incorporated into the extension cord 10. Typically,grounding wire 24 is locally grounded as opposed to being grounded atthe power source as is often the case for neutral wire 14 a of FIG. 2Aor wire 14 d of FIGS. 2B-2D.

In FIG. 2E, the extension cord 10 incorporates a number of femalesockets 20 q electrically connected to a neutral wire 14 a, a 120Vconducting wire 14 b, and a grounding wire 24. The extension cord 10also incorporates a number of female sockets 20 r electrically connectedto the neutral wire 14 a, the other 120V conducting wire 14 c, and thegrounding wire 24. Each female socket 20 q, 20 r resides within aseparate socket block, although it is understood that two or more femalesockets can be incorporated in each socket block consistent with theprinciples described above in FIG. 2C.

The socket blocks 22 each include ground fault circuit interrupters 30n-p coupled across the parallel connections to female sockets 20 p-r,which reside within the socket blocks 22. This configuration correspondsto the configuration of FIG. 2A, with inclusion of grounding wire 24.The ground fault circuit interrupters 30 n-p are not coupled across theparallel connection to the grounding wire 24. Current within thegrounding wire 24 is therefore not detected using the ground faultcircuit interrupters 30 n-p.

FIG. 2F has a similar three wire configuration to FIG. 2E, and alsoincludes grounding wire 24. Ground fault circuit interrupter 30 qcouples across and detects a zero sum across all of the conducting wires14 b-c and the neutral wire 14 a. Current within the grounding wire 24is not detected using the ground fault circuit interrupter 30 a. Upondetection of a fault, the ground fault circuit interrupter 30 qdisconnects the electrical supply to all of the female sockets 20 s-t.

The extension cords 10 of the present disclosure, especially those withelectrically isolated circuits, are especially useful when heavy powerdrawing devices or many electrically operated devices are attached tothe extension cord. The power load from these devices can be balancedbetween the two or more isolated circuits so that a single extensioncord can be used where two or more extension cords would otherwise berequired. By balancing the power load between the isolated circuits,devices may be plugged into a single extension cord and draw powerwhich, when plugged into a typical one circuit cord would otherwiseresult in tripping a fuse attached to the outlet or the cord; damage thecord or the equipment plugged into it; or even causing a fire. Balancingthe power load between the multiple circuits of the extension cordpermits more equipment to be operated safely with a single extensioncord. Ground fault circuit interruption associated with either the maleplug or the female sockets of the extension cords 10 provides additionalsafety to each female socket 20. By incorporation of ground faultcircuit interruption with each female socket, operation of all devicesconnected to the cord 10 is not interrupted upon detection of a fault atone female socket.

Alternatively, if the cord 10 has a separate neutral for each conductingwire, an embodiment can include a separate ground fault interruptercircuit for each separate circuit or pair of conductor and neutral wire.For example, if there are two conductors and two matching respectiveneutral wires, the cord can include two separate ground faultinterrupters 30. Thus if one circuit fails, the other circuit may stillbe operating and conducting electricity.

The alternative embodiments shown in FIGS. 2A-2F are merelyillustrative. It will be recognized that the same principles can be usedto construct extension cords and distribute ground fault circuitinterrupters across the cords for any voltage service that has two ormore conducting wires. In addition, all of the female socketsrepresented in each of FIGS. 2A-2F are not necessary for a cordconstructed according to the principles of the present disclosure. Forexample, an extension cord can be constructed similar to the embodimentdepicted in FIG. 2A by including only female sockets 20 a and 20 b. Sucha cord would have two electrically isolated circuits, one of which wouldprovide 120V service and the other 240V service. Extension cords can beconstructed having any combination of female sockets connected todifferent conducting wires and any combination of female sockets withina single socket block. One or more of the electrically isolated circuitsor female sockets can include ground fault circuit interrupters, invarious configurations as shown above, or a combination thereof.

Ground fault circuit interrupters operate in electrical installations todisconnect a circuit when imbalanced current flow is detected between aconducting wire and a neutral wire. GFI's open the circuit because animbalance might represent current through a person who is accidentallytouching the energized part of the circuit and is therefore about toreceive a potentially lethal shock. GFI's include a normally closedswitch connected to sense circuitry that is designed to open anddisconnect electricity quickly enough to prevent such shocks. FIGS. 3Aand 3B shows exemplary schematic views of portions of the extension cord10 of FIG. 2A including ground fault circuit interrupters 30 a and 30 c.

FIG. 3A shows ground fault circuit interrupter 30 a residing within thesocket block 22 and coupled across conducting wire 14 b and neutral wire14 a. The ground fault circuit interrupter includes a transformer 32,sense circuitry 34 electrically connected to the transformer 32, and aswitch 36 and solenoid 38 connected to the transformer 32 and sensecircuitry 34.

The transformer 32 detects current within both the conducting wire 14 band the neutral wire 14 a. In normal operation, all of the currentflowing along the conducting wire 14 b returns along neutral wire 14 b.This causes a balanced current state within the cord 10, and does notinduce any current in the transformer 32. In the case of a sudden changein current flow, for example caused by a person touching a livecomponent in the attached appliance, some of the current takes adifferent return path. This results in an imbalance in the currentflowing in the conductors 14 a and 14 b or, more generally, a nonzerosum of currents from among multiple conductors. This difference causes acurrent to flow in the transformer 32.

The sense circuitry 34 detects current flowing to it from thetransformer 32. The sense circuitry 34 activates the solenoid 38, whichin turn disconnects the switch 36, which in turn disconnects theconducting wire 14 b. Disconnecting the switch 36 opens the circuitdefined by the leads 14 a-b by disconnecting the conducting wire 14 b.The electricity supply to the circuit is interrupted, preventingpotential electrocution.

In a possible embodiment, optional resistor 40 and light emitting diode42 connect between the conducting wire 14 b and the return wire 14 a.The resistor 40 and light emitting diode 42 form an indicator circuitconfigured to illuminate the light emitting diode while the circuitconnected to the socket block 22 remains active. In an alternateembodiment, the light emitting diode 42 is replaced by an incandescentbulb or other illumination device. In still other embodiments, all or aportion of the socket block 22 is formed from a translucent material,and illuminates while the light emitting diode 42 remains illuminated.

FIG. 3B shows a ground fault circuit interrupter 30 b coupled acrossconducting wires 30 b-c. The ground fault circuit interrupter 30 boperates similarly to the ground fault circuit interrupter 30 a of FIG.3A, but is designed with switches 36 and solenoids 28 connected to thesense circuitry 34 to disconnect both of the conducting wires 14 b and14 c upon detection of imbalanced current flow. Such a configuration isuseful for multiphase power connections because it prevents accidentalpower transmission if the load connected to the female socket isaccidentally grounded.

The ground fault circuit interrupters are designed so that the currentis interrupted in a very short time after the imbalanced current isdetected, such as a fraction of a second. This greatly reduces thechances of an electric shock being received.

In additional possible embodiments ground fault circuit interrupters 30can sense current changes among more than two wires, and may requiredifferent electrical connections depending upon the configuration used.For example, a multiphase conducting wire cord may require more than oneswitch 36 connected to the sense circuitry 34. For clarity, the basicschematics shown in FIGS. 3A-3B are used throughout the presentdisclosure, but are understood to represent additional possibleconfigurations of ground fault circuit interrupter wiring.

Referring now to FIG. 4, a female socket 20 for use with a standard U.S.120V male plug from an electrically operated device is shown. In thisembodiment, the male plug 12 of the extension cord 10 has four prongs 44and is configured for attachment to a 120/240V service. One commonconfiguration for a male plug 12 to be used with a 120/240V service is atwist lock plug where the plug is inserted into an appropriate femaleoutlet, not shown, and then the male plug is twisted to securely fastenthe prongs 44 of the plug within the outlet. This type of male plugconfiguration ensures that the plug 12 does not come out of the outletby simply pulling on the plug 12. Although the plug 12 shown includesfour prongs 44, plugs with any number of prongs can be used in thistwist lock configuration.

An optional adapter 26 may be provided for adapting this embodiment ofthe extension cord for use with a 120V source. This adapter 26 has afemale portion configured to receive the male plug 12 of the extensioncord 10 and a male portion for plugging into a female outlet of a 120Vsource. If such an adapter were used, for example, with the extensioncord configuration of FIG. 2A, the adapter would include an electricalconnection between the two 120V conducting wires 14 b and 14 c so thatthey would be attached to the same prong of the adapter. When using thisadapter the electrically operated devices plugged into the extensioncord will all be part of the same circuit despite using couplingconfigurations illustrated in FIG. 2A due to the connection of the twocircuit wires in the adapter. Furthermore, instead of being a separateattachment, the adapter may alternatively be integrally coupled to thecord 10.

Other adapters may be provided for conversion between extension cords ofthe present disclosure and other voltage source configurations. Inaddition, adapters may be provided that will convert the prongconfiguration of the male plug of the extension cord to an appropriateconfiguration for use in another country or region.

FIG. 5A shows a socket block 22 with rectangular female sockets 20. FIG.5B shows a socket block 22 with circular female sockets 20. Other socketand socket block configurations are possible.

In one possible embodiment, a circuit identifying mark 28 is providedproximate each of the female sockets 20. The circuit identifying mark 28may be color-coded (see FIG. 5A), numbered, lettered (see FIG. 5B),stamped, or otherwise configured to indicate the circuit to which theproximate female socket is attached. The circuit identifying mark 28provides an extension cord user with information about which circuit thedevice is being plugged into so that the user may balance the power loadof the circuit.

In another possible embodiment, the circuit identifying mark 28 is alight emitting diode or other illumination device. The light emittingdiode is configured to illuminate upon connection of a male plug to thefemale socket 20, and is color coded to the circuit corresponding tothat socket.

FIGS. 5A and 5B both show socket blocks 22 for use with extension cordsin which the two female sockets 20 of the socket block 22 are eachattached to different circuits. However, other configurations are alsopossible including having the female sockets 20 of each socket block 22attached to the same circuit or alternatively, having more than onefemale socket in each socket block attached to the same circuit. Forexample, in one embodiment, not shown, two out of four female sockets ina socket block are attached to one circuit with the other two socketsattached to a second circuit.

FIG. 6 shows another alternative embodiment. In this embodiment one ormore of the female sockets 20 have a cap 50. Typically, there is a cap50 for each female socket 20. The cap 50 and female socket 20 areconfigured so that the cap 50 can be placed on or into female socket 20when the female socket 20 is not in use. The cap 50 provides a safetymechanism for the extension cord 10 to avoid unwanted contact betweenthe active conducting wires 14 a-14 g of the extension cord 10 andindividuals, moisture, or other external objects.

Additionally, a mooring member 52 is attached to either the femalesockets 20 or the socket blocks 22 which can be used to hold theextension cord 10 in place. For example, the mooring member 52 may beused to fasten the extension cord 10 in a desired place or position orto hold the extension cord 10 off the ground, as depicted in FIG. 7. Themooring member may be a loop or ring of material. Alternatively, themooring member may be a hook, strap, bracket, slot, or similar devicewhich will permit attachment of the cord to an external object. Themooring member 52 may be used with any extension cord, not only thosewith multiple circuits. In one embodiment, the mooring member isintegrally molded to the socket or socket block to provide a stable anddurable structure.

In an alternative embodiment, the extension cord is made of a male plug,two or more conducting wires electrically connected to the male plug,and one or more female sockets electrically connected to the conductingwires with a mooring member attached to the female sockets or to asocket block which houses the female sockets. In this embodiment, thefemale sockets may all be electrically connected to the same conductingwires, or alternatively, they may be electrically connected to differentconducting wires.

FIG. 8A shows an extension cord 210 including a male twist lock plug212. The extension cord 210 can be used in construction or other highvoltage applications. The cord 210 has a male twist lock plug 212, whichincludes a housing 213. The cord also includes a female twist locksocket 220, configured to mateably receive a male twist lock plug 212.In use, a male twist lock plug 212 is inserted into a female twist locksocket 20, and axially rotated (either clockwise or counterclockwise,depending upon the configuration of the plug and socket) into a lockedposition. Removal of the male plug 212 from the female socket 220requires twisting the male plug 212 in the opposite direction.

The male twist lock plug 212 includes a plurality of prongs 215 formedin a circular configuration to lockably mate with a female socket 220.The male twist lock plug 212 is twisted to securely fasten the prongs215 of the plug 212 within the outlet.

The male twist lock plug housing 213 has an oval cross-sectional shapeat its face or at any other point within the housing 213. The oval shapeof the housing 213 indicates the rotational position of the plug, whichin turn dictates whether the plug 212 is in a locked or unlockedposition when inserted into a female socket 220. In various embodiments,the plug 212 can be other non-circular shapes. Although the plug 212 canretain a circular configuration of the prongs 215, the housing 213 canhave a triangular, rectangular, or any other cross sectional shapecapable of indicating the rotational position of the plug 212. Infurther embodiments, the male twist lock plug 213 includes an indicatorwhich corresponds to an indicator on a corresponding female twist locksocket 220. Alignment of the indicators can indicate a locked orunlocked position of the male twist lock plug 212.

The female twist lock socket 220 optionally has an oval cross-sectionalshape as well. The oval shape of the female twist lock socket 220 alignswith the oval cross sectional shape of a male twist lock plug housing213 when in either a locked or unlocked position.

FIG. 8B shows a perspective side view of a section of an electrical cord210 including a male twist lock plug 212 with a housing 213 having anoval cross-sectional shape as described in FIG. 8A. Each of theplurality of prongs 215 connects to an internal conductor, such as theconducting or neutral wires 14 of FIGS. 2A-2E. The housing 213 has avariable-sized oval cross section, which indicates the rotationalposition of the plug, showing whether the plug 212 is in a locked orunlocked position when inserted into a female socket 220.

FIG. 8C shows a schematic functional view of a section of an extensioncord including a male plug 212 according to an embodiment of the presentdisclosure. The non-circular cross-section of the housing 213 enables auser to readily ascertain whether the plug is in a locked position. Inthe embodiment shown, the oval plug is inserted in an askew position,shown in FIG. 8C in dotted lines. The askew position corresponds to anunlocked, or insertion position. When the plug 212 is fully inserted andtwisted to the locked position, the oval shaped housing 213 is upright,allowing a user to readily determine the locked status of the plug 212.Alternately, the housing 213 can be in a locked position at a differentascertainable rotational position.

FIGS. 9A and 9B show schematic views of the male twist lock plug 212used in conjunction with a female socket 220 incorporated into anelectrical generator 300. The electrical generator 300 provides a powersource 302 that can be used at a construction site, a home, or otherlocation where a portable or backup power supply is desired. Theelectrical generator 300 generates an electrical current which passesthrough an electrical cord 210 associated with the male twist lock plug212 when the cord is connected to the electrical generator. Socketorientation indicia 221 located on a visible face of the socket 220and/or socket block 222 indicates the locked state, the unlocked state,or both the locked state and the unlocked state of the combination ofthe male plug 212 and female socket 220. The socket orientation indicia221 can include an outline displaying the cross-sectional shape of themale housing 213 when in the locked and/or unlocked positions.

Additional configurations of the socket orientation indicia 221 arepossible as well. For example, a colored indicator located on the maleplug can align with a colored indicator on the female socket when in alocked and/or unlocked position. In another alternative embodiment, thesocket orientation indicia 221 is defined by a portion of the face ofthe socket block 222 (or on the face plate enclosing the female socket)that is raised, elevated, or otherwise set-off relative to adjacentportions of the socket block or surrounding structure. The profile ofthe raised portion of the face plate would match the profile for theface of the male twist lock plug 212.

The female socket 220 can optionally be located within a socket block222 incorporated into the electrical generator 300. As shown in FIG. 9A,the socket block 222 can include a ground fault circuit interrupter 30associated with the female socket 220. In such a configuration, theground fault circuit interrupter 30 provides global ground faultprotection to any electrical cord plugged into the female socket 220.

FIG. 9B shows socket block 222 incorporated into the electricalgenerator 300 and including a female twist lock socket 220 includingsocket orientation indicia 221. A socket adapter 250 includes a maleplug 212′ used to connect to a twist lock female socket, such as thesocket 220 integrated with the electrical generator 300. The socketadapter further includes a female plug 220′ that can accept other maletwist lock plugs, such as the male plug 212 connected to the electricalcord 210.

Connection wires connect the male plug 212′ to the female socket 220′within a housing 213′ of the socket adapter 250. The socket adapter 250can optionally include a ground fault circuit interrupter 30electrically connected between a male plug 212′ and a female socket220′. The ground fault circuit interrupter 30 resides within the housing213′ of the socket adapter 250.

FIGS. 10A-10D show schematic views of an extension cord 410incorporating a thermal indicator circuit according to variousembodiments of the present disclosure. FIG. 10A shows the cord 410including a thermal indicator circuit 430 a located near a male plug 12.The cord 410 correlates to the cord 10 of FIG. 3B, in that a four wireconfiguration is shown. The thermal indicator circuit 430 a includes athermal switch 432 and an indicator 434.

The thermal indicator circuit 430 a connects across a conducting wire 14e and a neutral wire 14 d in the extension cord 410. Additional thermalindicator circuits can connect between the neutral wire 14 d and otherconducting wires 14 f-g, or between two conducting wires. The inclusionof a thermal indicator circuit 430 does not depend upon the specificconfiguration of the extension cord 410; two, three, or four or morewire cords can include thermal protection. In various embodiments, thethermal indicator circuit 430 a can be located within a housing 13 ofthe male plug 12 and/or the thermal indicator circuit can be locatedalong the extension cord 410.

The thermal switch 432 activates the thermal indicator circuit 430 whena temperature above a specific temperature is detected. In an exemplaryembodiment, the thermal indicator circuit 430 is activated withoutinterrupting electrical flow along the electrically conducting wires.For example, as an extension cord wears, added electrical resistanceoccurs at the wear areas of the cord 410. This added electricalresistance causes heat. Because cord degradation typically occurs nearplug and socket connections, fires and other thermal hazards generallyoccur in these places as well. The thermal indicator circuit 430provides a warning to a user of the cord 410 that potentially unsafetemperatures exist within potentially problematic locations within thecord. While the thermal indicator circuit 430 provides the warning, theelectrical flow along the electrically conducting wires continues to runand is not interrupted, although other embodiments can include a switchor other mechanism to open the circuit in the event the thermalindicator is tripped.

In one embodiment, the thermal switch 432 is a thermistor, such as anNTC switching thermistor. In an exemplary embodiment, a thermistor suchas an NTC switching thermistor, detects a specific temperature using thefollowing generalized equation (1):

$\begin{matrix}{T = \frac{1}{a + {b\;\ln\; R} + {c\left( {\ln\; R} \right)}^{3}}} & (1)\end{matrix}$where a, b, and c are device-specific parameters, T is the temperature,and R is the resistance of the thermistor. The threshold value for theresistance is selected to correspond to a temperature value at or belowa temperature limit for safe operation of the extension cord 410. Whenthe temperature reaches the threshold, the resistance reaches a lowenough level that the circuit is considered to be a “closed” circuit.Other temperature sensitive switches can be used as well. Althoughequation (1) is presented in this disclosure, various embodiments mayoperate according to physical and mathematical principles other thanthose described by equation (1).

The thermal switch 432 generally operates to connect a circuit upondetection of a minimum temperature. Thermal switches can includethermistors, which are variable-resistance resistors, whose resistancechanges according to its temperature. In one possible type ofthermistor, a negative temperature coefficient (NTC) thermistor, adecrease in resistance occurs as temperature increases. The thermistorcan be made from a semiconducting material, such as a metal oxide.Raising the temperature of such a thermistor increases the number ofcharge carriers in the thermistor. The more charge carriers that areavailable, the more current that can be conducted, and the lower theresistance of the material. In another possible type of thermistor, apositive temperature coefficient (PTC) thermistor, an increase inresistance occurs as temperature increases. Thermal switches generallyuse a switching thermistor (either NTC or PTC), which means that theresistance of the thermistor either rises or falls suddenly at a certaincritical temperature. This critical temperature is the criticaltemperature at which the thermal switch changes state. Other embodimentscan include a thermal switch other than a thermistor.

The indicator 434 is an electrically activated indicator perceptible toa user of the cord, and indicates when the temperature reaches aspecific threshold and the thermal switch 432 reaches its “closed”state. The indicator 434 activates upon activation of the thermal switch432. The indicator 434 can include a light, such as a light-emittingdiode, incandescent bulb, or other display or illumination device. Theindicator 434 can also include a fuse or circuit protection device. Theindicator 434 can include an audible alarm. A combination of indicatorscan be used in combination as well, such as multiple lights, a light andan audible alarm, a light and a fuse, or other configurations.Additionally, a light can be positioned within a housing that is atleast partially translucent.

FIG. 10B shows the cord 410 including a thermal indicator circuit 430 bthat reaches across the entire length L of the cord 410. The thermalswitch 432 spans the length of the cord 410, and can include one or moreindicators 434, such as one indicator at each end of the cord 410. Thethermal switch 432 activates the thermal indicator circuit 430 b byactivating the indicators 434 upon detection of the thresholdtemperature (or higher) at any location along the cord 410. In a furtherembodiment, the thermal indicator circuit 430 b spans less than theentire length L of the cord 410.

In the embodiment shown, both indicators 434 are the same type ofindicator. However, in alternate embodiments various types of indicatorscan be used in combination, such as an audible alarm and a lightemitting diode, or other combinations. In yet another possibleembodiment, the indicators are replaced by or positioned in electricalseries with a relay having contacts in line with conducting wire 14 eand an armature activated by the thermal switch 432. When the thermalswitch 432 is tripped, the armature moves the contacts and creates anopen circuit in the conducting wire 14 e.

FIG. 10C shows the cord 410 including multiple separate circuitsincluding female sockets 20 x-z, and corresponds to FIG. 3B, above, inthat it shows an embodiment of a cord 410 for use with a four-wireservice and including a number of socket blocks 22 dispersed along thecord 410. Each socket block 22 contains one or more female sockets 20a-c, which can be configured in a manner as described in conjunctionwith FIG. 3. Thermal indicator circuits 430 c-e reside near each socketblock 22, with at least a portion of the thermal switch 432 located nearthe junction of the socket block 22 with a flexible portion of the cord410 due to the high probability of wear at those locations. The thermalindicator circuits 430 c-e detect thermal degradation near each socketblock 22, such that a user of the cord 410 can choose to continue use ofthe cord 410 after one socket block 22 becomes unsafe by switching to aseparate electrically isolated socket block. The indicator 434 canreside within or be located separate from the socket block 22.

In an alternate configuration, a thermal indicator circuit 430 a can belocated proximate to the male plug 412, and is used in conjunction withthe thermal indicator circuits 410 c-e located near the female sockets20 x-z.

FIG. 10D shows the cord 410 including two thermal indicator circuits 430f-g. FIG. 10D corresponds to FIG. 10A, but includes a second thermalindicator circuit 430 g having different operation from the firstthermal indicator circuit 430 f.

Thermal indicator circuit 430 f includes a thermal switch 432 and anindicator 434. Thermal indicator circuit 430 g includes a thermal switch432′ and an indicator 434′. Thermal switches 432 and 432′ can differbased on threshold temperature, normal state (open or closed), or otherfactors. Indicators 434 and 434′ can be either the same or differentindicators selected from among the possible indicators described abovein conjunction with FIG. 10A.

In a first possible embodiment, second thermal indicator circuit 430 gis a warning circuit, and has a thermal switch 432′ with a lowerthreshold temperature than thermal switch 432 of thermal indicatorcircuit 430 f. A user of such a device is provided two levels ofseverity warnings for use of the electrical cord 410. In various otherembodiments, the thermal switch 432′ has inverse operation to theoperation of thermal switch 432. In one implementation of thisembodiment, thermal switch 432 is an NTC thermistor and thermal switch432′ is a PTC thermistor, and both switches 432, 432′ have the samethreshold temperature. The circuit 430 g remains normally connected,activating indicator 434′. When the temperature of the cord exceeds thethreshold temperature, thermal switch 432′ opens and deactivatesindicator 434′ in thermal indicator circuit 430 g, and thermal switch432 closes and activates indicator 434 in thermal indicator circuit 430f. In a possible embodiment, indicator 434′ can be a green lightemitting diode and indicator 434 can be a red light emitting diode.Illumination of the green light emitting diode indicates safe operationof the cord 410, and illumination of the red light emitting diodeindicates hazardous operation of the cord 410. Other configuration ofindicators and threshold temperatures are possible as well.

FIGS. 11A-11C show schematic views of various embodiments of anelectrical cord 440 incorporating a thermal indicator circuit 430 intoan electrical cord 440. The electrical cord 440 connects to anelectrical tool 450, and can be either an extension cord as described inFIGS. 10A-C, or can be non-detachably incorporated onto the electricaltool 450. The electrical tool 450 can be any of a number of constructiontools, such as a rotary saw, a sander, nail gun, drill, or othermachinery. The electrical tool 450 can also be unrelated toconstruction, and can be any other type of electrical device whichtypically draws a high current or where cord wear could be a concern.Such devices could include, for example, a hair dryer, a microwave orother appliance, a vacuum, or other devices.

FIG. 11A corresponds to FIG. 10A incorporated with an electrical tool450, and shows the electrical cord 440 including a thermal indicatorcircuit 430 a near or integrated with a male plug 12 as previouslydescribed. FIG. 11B corresponds to FIG. 10B incorporated with anelectrical tool 450, and shows the electrical cord 440 including athermal indicator circuit 430 b spanning the length L of the electricalcord 440 between the male plug 12 and the electrical tool 450. FIG. 11Ccorresponds to both FIGS. 10A and 10C, and shows the electrical cord 440including a thermal indicator circuit 430 a proximate to the male plug12 and a second thermal indicator circuit 430 c proximate to theelectrical tool 450.

In each of the embodiments shown, the thermal indicator circuit 430 isconnected across the neutral wire 14 d and conducting wire 14 e. Inalternate configurations of the electrical tool, additional thermalindicator circuits 430 connect between the neutral wire 14 d and adifferent conducting wire 14 e-f in the electrical cord 440. Theelectrical cord 440 can include more or fewer conducting wires 14, andcan include a ground wire (not shown).

FIG. 12 shows an exemplary extension cord 460 having a male plug 461,one or more female sockets 463 a and 463 b, and an electrical conductor465. A thermochromatic material 462 forms a thermal indicator and ismounted on or integrated into the extension cord 460 at one or morelocations 462 a-462 h. The thermochromatic material 462 can be formedwith any type of temperature sensitive material that changes color inresponse to temperature as described herein. Examples of possiblethermochromatic materials include thermochromatic liquid crystals,polymers, paints, dyes, and inks.

The thermochromatic material 462 can have different forms and can beapplied to the extension cord 460 in different ways. For example, thethermochromatic material 462 can be in the form of a tape, label, orother substrate having an adhesive backing that is applied to thesurface of the extension cord 460. In another possible embodiment, thethermochromatic material 462 can be a coating or material such aspolymer, liquid crystal, paint, dye, or ink applied directly toextension cord 460. In this embodiment, the thermochromatic material 462can be applied to the surface of the extension cord 460 by any suitabletechniques such as brushing, spraying, or otherwise depositing it ontothe surface of the extension cord 460. Alternatively, the male plug 461,one or more female sockets 463 or insulator on the conductor 465 isformed, at least in part, with the thermochromatic material 462 moldedinto the extension cord 460. In these embodiments, the thermochromaticmaterial 462 is applied to the male plug 461 (e.g., thermochromaticmaterial 462 a), one or more of the female sockets 463 (e.g.,thermochromatic material 462 g and 462 h), the conductor 465(thermochromatic material 462 b-462 f), or any combination thereof.

The thermochromatic material 462 can have different sizes and shapes.Thermochromatic material 462 can be applied to the extension cord 460during the manufacturing process or provided to users to apply to theextension cords 460 as an after-market product. Additionally,thermochromatic materials 462 having different sizes and shapes can bepositioned at different locations along a single extension cord 460.

In use, the thermochromatic material 462 changes a color upon detectinga temperature at or above a threshold temperature of the extension cord460 so that it provides a warning that the extension cord 460 might beover-heated. When the portion of the extension cord 460 proximal to thethermochromatic material 462 has a temperature below the thresholdtemperature, the color of the thermochromatic material 462 has a firstcolor. When the portion of the extension cord 460 proximal to thethermochromatic material 462 reaches a temperature at or above thethreshold temperature, the color of the thermochromatic material 462changes to a second color which is different from the first color.

In an exemplary embodiment, once the temperature of the extension cord460 proximal to the thermochromatic material 462 decreases and becomeslower than the threshold temperature, the thermochromatic material 462changes its color from the second color back to the first color. Inanother exemplary embodiment, the color of the thermochromatic material462 does not return to its original color even after the temperaturefalls below the threshold value. An advantage of applying athermochromatic material 462 to an extension cord is that it canindicate when the extension cord 460 has reached such a temperature asto become a fire hazard.

In an alternative embodiment, the thermochromatic material 462 can bemade to change a color when the temperature reaches multiple differenttemperature thresholds so that multiple warnings can be given to a user.For example, when the temperature of the extension cord 460 reaches orexceeds a first threshold temperature, the thermochromatic material 462changes its color from a first color (e.g., green) to a second color(e.g., orange). This first color gives a user a first warning. When thetemperature of the extension cord 460 continues to rise and reaches asecond threshold, the temperature sensitive sheet 462 changes its colorfrom the second color (orange) to a third color (e.g., red) and givesthe user a second level warning which is more serious than the firstwarning regarding over heating of the extension cord 460. Thethermochromatic material 462 can further be configured to change fromany number of colors to different colors when the temperature reaches adifferent threshold temperature and then give more levels of warnings asdescribed above. In another possible embodiment, the color of thethermochromatic material 462 may change continuously in responding tothe continuous changes of the temperature.

In one possible application, the thermochromatic material 462 is appliedto locations of the extension cord 460 that are most likely subject tofailure or resistive heating. Examples of such locations are where theelectrical current flows from one electrical conductor to another or thecord is most commonly subject to twisting and bending. Examples of suchlocations include the male plug 461, the female sockets 463, and theportion of the insulator on the conductor 465 that is adjacent to themale plug 461 and the female sockets 463. In other possible embodiments,the thermochromatic material 462 extends along substantially the entirelength of the extension cord 460.

Although the thermochromatic material 462 is illustrated as beingapplied to an extension cord having intermittently spaced female socketsand anchors, it could be applied to many other types of cords. Forexample, the thermochromatic material 462 can be applied to extensioncords having a single female socket or socket block, power cords forelectrical devices, and the like.

Referring now to FIGS. 13A, 13B, 14A, and 14B an alternative embodimentof the extension cord 500, includes a female socket 520 mounted on anelectrical conductor 518 having an adjustable anchor 550 that can pivotbetween at least two positions to enable the extension cord 500 to beeither suspended or mounted on a vertical surface such as a wall, studs,or posts. The anchor 550 includes first and second anchor members 551and 552, which are pivotally connected to a housing 514 of the femalesocket 520 by first and second pivots 573 and 574, respectively. Thefirst anchor member 551 defines a first void 553 and has a first surface591. The second anchor member 552 defines a second void 554 and has asecond surface 592. The first and second voids 553 and 554 are sized toreceive a hanger for suspending the extension cord 500 and alternativelya fastener such as a screw, nail, pin, or peg to mount the extensioncord 500 on a vertical surface. In the exemplary embodiment, the femalesocket 520 has a generally tear-drop shape configuration. Although theexemplary embodiment illustrates the adjustable anchor as forming a partof the female socket block, other embodiments will have adjustableanchors positioned along the extension cord at locations other than afemale socket.

When the anchor 550 is in a first or closed position (illustrated inFIGS. 13A and 13B), the first and second surfaces 591 and 592 of thefirst and second anchor members 551 and 552, respectively, are directlyadjacent to one another and the first and second voids 553 and 554 areaxially aligned to one another. In a second or open position(illustrated in FIGS. 14A and 14B), the first and second surfaces 591and 592 are coplanar and the voids 553 and 554 are parallel to oneanother and are orthogonal to the first and second surfaces 591 and 592.The first and second anchor members 551 and 552 can be pivoted betweenthe first and second positions or any other position such as in a 90°arrangement to adapt to a corner. The adjustable anchor 550 providesflexibility to allow the extension cord to be suspended or mounted on avariety of different surfaces having a variety of different orientationsand shapes.

In an exemplary embodiment, the anchor 550 is spring-loaded. Forexample, the anchor 550 includes first and second springs 575 and 576which extend around the pivots 573 and 574, respectively, and betweenthe first and second members 551 and 552 and the housing 514,respectively. The first and second springs 575 and 576 bias the firstand second members 551 and 552 into the first or closed position.Alternative embodiments do not include springs 575 and 576 and the firstand second anchor members 551 and 552 are not biased to any particularposition. Any suitable structure that biases the first and second anchormembers 551 and 552 can be used such as other spring structures. Theanchor 550 can also be formed with a resilient material that naturallyurges the anchor members 551 and 552 to a predetermined position. Inanother alternative embodiment, the first and second anchor members 551and 552 are biased into the second or open position.

In another possible embodiment, the first and second anchor members 551and 552 engage the housing 514 with a snap fit when in the first orclosed position as described herein. The snap fit can be formed with anysuitable structure such as nubs (not shown) on the first and secondanchor members 551 and 552 and mating depressions (not shown) in thehousing 514. The snap fit holds the first and second anchor members 551and 552 in the closed position so that the first and second voids 553and 554 remain aligned even when a user is not directly grasping theanchor 550. In another embodiment, the anchor 550 includes a snap fitstructure that holds the first and second anchor members 551 and 552 inthe second or open position. An advantage of this embodiment is that itcan make the female socket 520 and anchor 550 easier to handle whenmounting it on a surface as described below in conjunction with FIG. 15,especially if the first and second anchor members 551 and 552 are biasedin the closed position.

FIGS. 15 and 16 illustrate alternative ways to use the extension cord500 and the flexibility provided by the anchor 550. The extension cord500 includes a male plug 512, a conductor 518, and a plurality of femalesockets 520 a-520 d. In FIG. 15, the first and second anchor members 551a-551 d and 552 a-552 d are in the second or open position so that thefirst and second surfaces 591 and 592 for each anchor member 551 and 552are coplanar and positioned against a vertical surface 593 such as awall. The first and second anchor members 551 a-551 d and 552 a-552 dare held in place by fasteners 571 a and 571 a′-571 d and 571 d′,respectively, that extend through the first and second voids 553 and 554and are attached to the vertical surface 593. The illustrations show thefasteners 571 as screws, but other fasteners or similar structures canbe used such as nails, pins, hooks, pegs, and the like. Additionally,the anchors 550 a-550 d can be attached to structures other than wallssuch as studs, posts, and the like. In FIG. 16, the first and secondanchor members 551 a-551 d and 552 a-552 d are in the first or closedpositions so the first and second voids 553 a-553 d and 554 a-554 d areaxially aligned. The extension cord 500 is then suspended by hooking theanchors 550 a-550 d on a hook 581 a-581 d, respectively, that passesthrough the first and second voids 553 a-553 d and 554 a-554 d. Thehooks 581 a-581 d can be attached to an overhead structure 599 such as aceiling or rafters. Alternatively the hooks 581 a-581 d can extend froma wall, from stakes planted in the ground, or from any other structurethat can support the extension cord 500. Also, any structure other thana hook that can pass through the voids 553 a-553 d and 554 a-554 d canbe used. An advantage of these cords is that they can be mounted on orsuspended from many different types and orientations of surfaces, whichallows the cords to be positioned in safe and convenient locations.

FIG. 17 is a view of an electrical adaptor 600 that includes a housing634 and three electrical connectors 636, 637, and 638 which arepositioned in the housing 634. The three electrical connectors 636, 637,and 638 are in electrical communication with each other. The firstelectrical connector 636 is substantially axially aligned with thesecond electrical connector 637. In addition, the third electricalconnector 638 is positioned generally orthogonal to the first electricalconnector 636 and the second electrical connector 637. The firstelectrical connector 636 is a male electrical plug. The second and thirdelectrical connectors 637 and 638 are female electrical sockets. Inalternative embodiments, each of the first, second, third connectors636, 637, and 638 can be either a male electrical plug or a femaleelectrical socket.

The electrical adaptor 600 also includes fasteners 608 a and 608 bpositioned proximate to the first electrical connector 636 (male plug)and pivotally connected to the housing 634 and adapted to secure thehousing 634 to an extension cord (shown in FIG. 19). The electricaladaptor 600 also includes engaging structures 639 a-639 d proximal tothe second and third electrical connectors 637 and 638 (female sockets)configured to engage, receive, catch, or otherwise mate with a fastener(similar to fastener 608) from other extension cords or power cords fromelectrical devices. In the exemplary embodiment, the engaging structures639 a-639 d are depressions defined in the housing 634 and arranged toreceive the fastener. In alternative embodiments, the engagingstructures 639 a-639 d are protruding flanges (not shown) or othersuitable structure configured to be caught or otherwise engaged by afastener (similar to fastener 608) from other extension cords, powercords, or electrical devices. Although the illustrated embodiment showsthe fasteners 608 a and 608 b proximal to the male electrical plug andthe engaging structures 639 a-639 d proximal to the female sockets,other embodiments could reverse this arrangement so the fasteners 608 aand 608 b is positioned proximal to the female sockets and the engagingstructures 639 a-639 d are positioned proximal to the male plugs.

In alternative embodiments, the fasteners 608 a and 608 b are biased toa closed position so that the second portions 624 (described below) foreach fastener 608 a and 608 b are urged toward one another and towardthe center of the housing 634 at the site of the electrical connector636. In various embodiments, the fasteners 608 a and 608 b can be springloaded to create the bias or can be formed with a resilient materialthat naturally returns to the biased position. Additionally, in otherembodiments the fasteners engage the housing 634 with a snap fit such ascan be formed with a nub and depression arrangement. The snap fitstructure can be positioned to hold the fasteners 608 a and 608 b in theopen position, the closed position, or both.

In one possible embodiment, the electrical adaptor 600 also includes ananchor 640 operably connected to the housing 634. The anchor 640 isformed by a hole 649 which is defined in the housing 634. The housing634 includes a projecting member 651 to form the anchor 640 and theprojecting member 651 defines the hole 649. In another possibleembodiment, the anchor 640 is substantially similar to the anchordiscussed above for example in FIGS. 13A, 13B, 14A, and 14B. In analternative embodiment, the anchor 640 is an adjustable anchor asdescribed in more detail herein.

Generally, the anchor 640 and the third electrical connector 638 arepositioned on substantially opposite sides of the housing 634. In onepossible embodiment, the anchor 640 is positioned about half way betweenthe first electrical connector 636 and the second electrical connector637. In alternative embodiments, the anchor 640 can be positionedanywhere along the electrical adaptor 600.

Referring now to FIGS. 18A-18B, the fastener 608 has a pivot 623 thatpivotally connects to the housing 634 of the electrical adaptor 630. Thefastener 608 has a generally L-shaped member 633 with a first portion622 and a second portion 624. The fastener 608 pivots around the pivot623 so the second portion 624 selectively engages an engaging structure(similar to engaging structure 639) on another electrical adaptor,extension cord, power cord, or electrical device. The fastener 608 alsohas a knob or other projecting member 625 generally parallel to thesecond portion 624 and projecting from the first portion 622 in adirection opposite to the second portion 624. The projecting member 625provides a structure for a user to engage with their finger and pivotthe fastener 608 around the pivot 623.

The fasteners 608 can have any type of structure that allows a male plugon an electrical adaptor, extension cord, power cord, or electricaldevice to be secured to a female socket on another electrical adaptor,extension cord, power cord, or electrical device. In lieu of theL-shaped structure illustrated, for example, the fastener 608 can beformed with clips, threaded structures such as nuts or collars, prongs,elastic bands, hook and loop fasteners such as VELCRO® brand fasteners,and the like. Additionally, the engaging structure 639 can be anystructure that engages the mating fastener to secure together male plugsand female sockets. Examples other than the illustrated depressioninclude flanges, thread structures, elastic bands, hook and loopfasteners, and the like. In yet other embodiments, the fastener 608 maybe able to secure a male plug to a female socket without an engagingstructure 639.

FIG. 19 is a view of the electrical adaptor 600 including two extensioncords 642 and 646. Each of the extension cords 642 and 646 hasintermittently spaced female sockets (not shown) and anchors (not shown)as described in more detail herein, although extension cords having asingle female socket can be used. The first extension cord 642 has afemale socket 699 connected to the first electrical connector 636 whilethe second extension cord 646 has a male plug 698 connected to thesecond electrical connector 637. The female socket 699 of the firstextension cord 642 has engaging structures 639 e and 639 f to mate withthe fasteners 608 a and 608 b, respectively. The second extension cord646 has fasteners 608 c and 608 d that mate with the engaging structures639 a and 639 b, respectively when the second extension cord 646connects to the second electrical connector 637. In addition, a thirdextension cord or electrical device (not shown) can be connected to thethird electrical connector 638.

Additionally, alternative embodiments of the electrical adaptor 600 caninclude any number of electrical connectors and any combination of maleplugs and female sockets. Additionally, the electrical connectors (e.g.,male plugs and female sockets) can have any orientation with respect toeach other including being parallel, orthogonal, or angled. The housing634 also can have many different configurations other including at-shape, linear shape, cross, and a 90° bend or corner shape.

Referring to FIG. 20, for example, an electrical adaptor 610 is similarto the electrical adaptor 600 shown in FIG. 17 except that theelectrical adaptor 610 has a linear housing 611 and only first andsecond electrical connectors 616 and 617 positioned at opposite ends ofthe housing 611. The first and second electrical connectors 616 and 617are substantially axially aligned with each other. The first electricalconnector 616 is a male electrical plug. The second electrical connector617 is a female electrical socket. Fasteners 608 a and 608 b arepositioned proximal to the first electrical connector 616 and anengaging structure 639 is positioned proximal to the second electricalconnector 617. In the exemplary embodiment, the engaging structure 639is a groove defined in and extending around the entire circumference ofthe housing 611. The electrical adaptor 610 has an anchor 640.

FIG. 21 shows an electrical adaptor 620 similar to the electricaladaptor 600 shown in FIG. 17 except that the electrical adaptor 620 hasa fourth electrical connector 641 that is orthogonal to the first,second, and third electrical connectors 636, 637, and 638. The fourthelectrical connector 641 is positioned between the first electricalconnector 636 and the second electrical connector 637. In alternativeembodiments, the electrical connectors 636, 637, 638, and 641 can be anycombination of male plugs and female sockets.

The electrical adaptors described herein can be used with many differenttypes of extension cords including extension cords having intermittentlyspaced female sockets and/or intermittently spaced anchors. When usedwith extension cords having intermittently spaced anchors, the anchor640 on the electrical adaptor 600 provides a location to suspend thestring of extension cords proximal to the connection between the maleplug of one cord and the mating female socket of the other cord so thatthe string of extension cords is supported at that location. Forextension cords that have intermittently spaced anchors, but do not haveany anchor proximal to the male plug or last female socket, electricaladaptors having an anchor 640 provide a way to further support the cordsso the male connector receives support and does not hang downsignificantly lower than other portions of the extension cords.Additionally, the electrical adaptor 600 enables users to assemble anetwork of extension cords to establish a power distribution networkthat can be suspended over head, extend along vertical surfaces such aswalls or studs, or simply suspended off of the ground on stakes platedin the ground to keep the extension cords out of puddles and other dampsurfaces.

The electrical adaptors and extension cords also can be used with thetemporary light fixtures described in more detail herein to set uptemporary and/or emergency lighting at constructions sights.Alternatively, a networks or string of extension cords can be assembledwith lighting fixtures connected to only some of the female sockets toprovide both temporary lighting and access to electricity for otherelectrical devices such as tools. Furthermore, the fasteners describedherein provide a mechanism to hold the various components together sothey do not become inadvertently disconnected causing a sudden andunexpected loss of power that is potentially both inconvenient anddangerous.

Referring now to FIG. 22, a temporary lighting fixture 700 includes ahousing 702, a light-bulb socket 704, a male electrical plug 706 andfasteners 708 a and 708 b. The light-bulb socket 704 is positioned inthe housing 702. The male electrical plug 706 is in electricalcommunication with the light-bulb socket 704. The fasteners 708 a and708 b are operatively connected to the housing 702 and the fastener 708is adapted to secure the housing 702 to a female socket on an extensioncord, electrical adaptor, or other electrical device. The fasteners 708a and 708 b have substantially similar structure as the fastener 608discussed in more detail herein and is configured to mate with anengaging structure similar to the engaging structure 639 also describedin more detail herein.

The temporary lighting fixture 700 also includes a protective cover 710.The protective cover 710 is operatively connected to the housing 702. Inaddition, the protective cover 710 defines a void 712 for receiving alight-bulb (not shown) to be connected to the light-bulb socket 704. Inone possible embodiment, the protective cover 710 has a basket orlattice structure. In other possible embodiments, the protective cover710 is a translucent plastic or glass enclosure.

In the exemplary embodiment, the temporary lighting fixture 700 alsoincludes a female electrical socket 714 which is positioned in thehousing 702 and in electrical communication with the male electricalplug 706. The female electrical socket 714 also includes an engagingstructure (not shown) to mate with a fastener on an extension cord,power cord, or electrical device. The engaging structure is similar toengaging structure 639 described herein, and the fastener is similar tothe fastener 608 described herein.

The various embodiments described above are provided by way ofillustration only and should not be construed to limit the claimsattached hereto. Those skilled in the art will readily recognize variousmodifications and changes that may be made without following the exampleembodiments and applications illustrated and described herein, andwithout departing from the true spirit and scope of the followingclaims.

1. A temperature sensing extension cord comprising: an extension cordhaving a cord comprising an electrical conductor, the extension cordfurther having a male electrical plug in electrical communication withthe electrical conductor, and a female socket in electricalcommunication with the electrical conductor; and a thermochromaticmaterial in contact with at least a portion of the cord of the extensioncord, the thermochromatic material configured to change from a firstcolor to a second color upon detecting a temperature at or above athreshold temperature and without interrupting the electricalcommunication between the male plug and the female socket.
 2. Thetemperature sensing extension cord of claim 1 wherein the thermochromatic material changes to a third color upon detecting a temperatureat or above a second threshold temperature.
 3. The temperature sensingextension cord of claim 1 wherein the thermochromatic material ispositioned on the male electrical plug.
 4. The temperature sensingextension cord of claim 1 wherein the thermochromatic material ispositioned on the female socket.
 5. The temperature sensing extensioncord of claim 1 wherein the electrical conductor is protected by aninsulator and the thermochromatic material is positioned on theinsulator.
 6. The temperature sensing extension cord of claim 5 whereinthe thermochromatic material is positioned proximal to the male plug. 7.The temperature sensing extension cord of claim 5 wherein thethermochromatic material is positioned proximal to the female socket. 8.The temperature sensing extension cord of claim 1 wherein thethermochromatic material extends along substantially the entire lengthof the extension cord.
 9. The temperature sensing extension cord ofclaim 1 wherein the thermochromatic material is on one side of asubstrate and an adhesive is on the opposite side of the substrate andthe adhesive adheres to the extension cord.
 10. The temperature sensingextension cord of claim 1 wherein the thermochromatic material isapplied directly to the extension cord.
 11. The temperature sensingextension cord of claim 10 wherein at least a portion of the extensioncord is molded and the thermochromatic material is molded into theextension cord.
 12. A method of monitoring the temperature of anextension cord having a cord, the method comprising: applying athermochromatic material to at least a portion of the cord of theextension cord; sensing a temperature of at least a portion of theextension cord with the thermochromatic material; and changing a colorof the thermochromatic material upon detecting a temperature at or abovea threshold temperature without interrupting the flow of electricalcurrent along the extension cord.
 13. The method of claim 12 whereinsensing the temperature includes sensing the temperature proximal to themale electrical plug.
 14. The method of claim 12 wherein sensing thetemperature includes sensing the temperature proximal to a femaleelectrical socket.
 15. The method of claim 12 wherein sensing thetemperature includes sensing the temperature along substantially theentire length of the extension cord.
 16. The method of claim 12 whereinapplying a thermochromatic material includes adhering a substrate to theextension cord.
 17. The method of claim 12 wherein applying athermochromatic material includes applying the thermochromatic materialdirectly onto the extension cord.
 18. The method of claim 12 whereinapplying a thermochromatic material includes molding the thermochromaticmaterial into the extension cord.